Lean Foundations and Principles

lean

removes waste and improves flow; used for poor process flow, inefficiency, and waste

six sigma

reduces variation and ensures consistency; uses data and statistical methods to identify/eliminate waste

kanban

maintain and improve efficiency through visual work management like boards and column-arranged tasks

8 types of waste (TIMWOODS)

transportation, inventory, motion, waiting, overproduction, overprocessing, defects, and skills

Non value added activity

consumes resources without adding customer value

value

define what customer values and is willing to pay for

value stream mapping (VSM)

provides a comprehensive overview, identifies delays, recognizes time gaps, and tracks progress overtime; includes value and non value added activities

Necessary non value added activities

activities for legal, regulatory, or business reasons; compliance documentation; & improvement in compliance areas

Poka-yoke

smart process design; make errors unlikely or impossible; build quality into the process

5 principles of lean

value, value stream, flow, pull, & perfection

perfection

reflects mindset of continuous improvement

value stream

all steps that deliver customer value

Just in time production (JIT) or pull

produce exactly what is needed and when it's needed

value added activity

one a customer is willing to pay for

flow

ensure value-creating steps move without delays or interruptions

kaizen

a mindset of continuous improvement; focus on small changes that are easy to apply/maintain